U.S. patent application number 13/064685 was filed with the patent office on 2012-10-04 for gears and its process of manufacture.
This patent application is currently assigned to NIPPON STEEL CORPORATION. Invention is credited to Yuji Adachi, Susumu Kato, Shuji Kozawa, Manabu Kubota, Koji Obayashi, Hirokazu Sato, Keita Taguchi.
Application Number | 20120247249 13/064685 |
Document ID | / |
Family ID | 47225781 |
Filed Date | 2012-10-04 |
United States Patent
Application |
20120247249 |
Kind Code |
A1 |
Obayashi; Koji ; et
al. |
October 4, 2012 |
Gears and its process of manufacture
Abstract
A method of manufacturing a gear, and the resulting gear, the
method resulting such that the surface layer portions of the tooth
portions and a tooth root portion are made to be a carburized
layer, the remaining portion of the tooth portions and a portion of
a disk portion lying below the carburized layer be a
quench-hardened layer, and a region of the disk portion lying
deeper than the quench-hardened layer be an unquenched layer. The
gear is manufactured using raw material steel having the following
chemical composition: C: 0.1% to 0.40% (% by mass), Si: 0.35% to
3.0%, Mn: 0.1% to 3.0%, Cr: less than 0.2%, Mo: 0.1% or less, P:
0.03% or less, S: 0.15% or less, Al: 0.05% or less, N: 0.03% or
less, and Fe and unavoidable impurities.
Inventors: |
Obayashi; Koji; (Toyoake,
JP) ; Taguchi; Keita; (Agui, JP) ; Kato;
Susumu; (Anjyo, JP) ; Kozawa; Shuji; (Muroran,
JP) ; Kubota; Manabu; (Muroran, JP) ; Adachi;
Yuji; (Tokai, JP) ; Sato; Hirokazu; (Tokai,
JP) |
Assignee: |
NIPPON STEEL CORPORATION
Tokyo
JP
AISIN AW CO., LTD.
Anjo-shi
JP
|
Family ID: |
47225781 |
Appl. No.: |
13/064685 |
Filed: |
April 8, 2011 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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PCT/JP2011/057937 |
Mar 30, 2011 |
|
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13064685 |
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Current U.S.
Class: |
74/434 ;
148/210 |
Current CPC
Class: |
Y10T 74/1987 20150115;
Y10T 74/19949 20150115; H01L 51/052 20130101; H01L 51/107
20130101 |
Class at
Publication: |
74/434 ;
148/210 |
International
Class: |
F16H 55/17 20060101
F16H055/17; C23C 8/80 20060101 C23C008/80 |
Claims
1. A gear, comprising: a disk portion; and a plurality of tooth
portions that are circumferentially formed in a discrete manner on
the disk portion, wherein the gear is subjected to carburizing
treatment and then quenching treatment by high-density energy
heating after formation of the gear, wherein raw material steel of
the gear has the following chemical composition: C: 0.1% to 0.40%
by mass; Si: 0.35% to 3.0% by mass; Mn: 0.1% to 3.0% by mass; Cr:
less than 0.2% by mass; Mo: 0.1% or less by mass; P: 0.03% or less
by mass; S: 0.15% or less by mass; Al: 0.05% or less by mass; N:
0.03% or less by mass; and Fe and unavoidable impurities:
remainder, a surface layer portion of each of the tooth portions
and a surface layer portion of a tooth root portion that is a
portion between the tooth portions on the disk portion are made, by
the carburizing treatment, to have a higher C concentration than
the C concentration of the raw material steel, and are made to be a
first quench-hardened layer that includes a martensitic structure,
a region covering a portion of each of the tooth portions other
than the portion serving as the first quench-hardened layer, a
portion of the disk portion lying below the first quench-hardened
layer of the tooth root portion, and a portion of the disk portion
lying below the tooth portions is made to have a C concentration
the same as the C concentration of the raw material steel, and is
made to be a second quench-hardened layer that includes a
martensitic structure, and a region of the disk portion lying
deeper than the second quench-hardened layer is made to have a C
concentration the same as the C concentration of the raw material
steel, and is made to be an unquenched layer that includes no
martensitic structure.
2. The gear according to claim 1, wherein the C concentration of
the first quench-hardened layer is 0.60% to 0.85% by mass on a
surface thereof and is gradually reduced inside toward a boundary
with the second quench-hardened layer.
3. The gear according to claim 1, wherein the chemical composition
of the raw material steel further contains: Ti: 0.005% to 0.2% by
mass and B: 0.0006% to 0.005% by mass.
4. The gear according to claim 1, wherein Mo content in the
chemical composition of the raw material steel is less than
0.01%.
5. The gear according to claim 1, wherein the chemical composition
of the raw material steel further contains either or both of: Nb:
0.01% to 0.3% by mass and V: 0.01% to 0.2% by mass.
6. The gear according to claim 1, wherein the chemical composition
of the raw material steel further contains Ni: 0.1% to 3.0% by
mass.
7. A method for manufacturing a gear that includes a disk portion
and a plurality of tooth portions circumferentially formed in a
discrete manner on the disk portion, raw material steel of the gear
having the following chemical composition: C: 0.1% to 0.40% by
mass; Si: 0.35% to 3.0% by mass; Mn: 0.1% to 3.0% by mass; Cr: less
than 0.2% by mass; Mo: 0.1% or less by mass; P: 0.03% or less by
mass; S: 0.15% or less by mass; Al: 0.05% or less by mass; N: 0.03%
or less by mass; and Fe and unavoidable impurities: remainder, the
method for manufacturing a gear comprising: a carburizing process
of forming a carburized layer on a surface of the gear formed of
the raw material steel, the carburized layer being formed by
heating the gear to or above an austenitizing temperature of the
raw material steel in a carburizing atmosphere of a lower oxygen
concentration than an oxygen concentration of the atmosphere; a
cooling process of cooling the gear after the carburizing process
at a lower cooling rate than a cooling rate at which the raw
material steel is transformed into martensite, to or below a
temperature at which structural transformation by cooling is
completed; and a quenching process of heating the gear after the
cooling process by high-density energy heating so as to increase
the temperature of a region lying shallower than a core portion of
the disk portion and of the tooth portions to or above the
austenitizing temperature of the raw material steel without
increasing the temperature of the core portion of the disk portion
to or above the austenitizing temperature of the raw material
steel, and cooling the gear of that state at or above the cooling
rate at which the raw material steel is transformed into martensite
so as to form a martensitic structure in the region lying shallower
than the core portion of the disk portion and in the tooth
portions.
8. The method for manufacturing a gear according to claim 7,
wherein that the carburizing process is performed under a condition
under which the carbon concentration in the carburized layer after
a diffusion period in the carburizing process is 0.85% or less by
mass.
9. The method for manufacturing a gear according to claim 8,
wherein the gear on which the carburizing process is performed
includes a first portion and a second portion with different
diffusion rates of carbon having infiltrated during carburizing
treatment because of shapes thereof, the diffusion rate of carbon
having infiltrated being lower in the second portion than in the
first portion, and the carburizing process is performed under a
condition under which the carbon concentration in the carburized
layer after a diffusion period in the carburizing process is in a
range of 0.65%.+-.0.1% by mass.
Description
INCORPORATION BY REFERENCE
[0001] The disclosure of Japanese Patent Application No.
2010-079437 filed on Mar. 30, 2010 including the specification,
drawings and abstract is incorporated herein by reference in its
entirety.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to a gear, such as a
differential ring gear in a vehicle drive train system, that is
used for transmitting such high torque as to produce a stress not
only in a surface layer portion but also in a core portion, and to
a manufacturing method of the gear. More in detail, the present
invention relates to a gear that is made of steel as raw material
and is hardened through processes such as carburizing and
quenching, and to a manufacturing method of the gear.
DESCRIPTION OF THE RELATED ART
[0003] A steel member such as a gear is often processed with
carburizing and quenching treatment serving as treatment for
increasing the surface hardness while maintaining the toughness of
the steel member. Hereinafter, a steel member processed with
carburizing treatment will be referred to as a carburized steel
member where appropriate. The carburizing and quenching treatment
is a treatment for increasing the surface hardness of a steel
member while ensuring the toughness of a core portion of the steel
member by quenching the steel member after applying to the steel
member carburizing treatment to increase the surface carbon
concentration of the steel member in the state in which the steel
member is heated to the austenitizing temperature or higher.
Various methods have been proposed heretofore as methods for
manufacturing a steel member by applying the carburizing and
quenching treatment. For example, in WO 2006/118242, steel raw
material containing Cr and Mo is subjected to processes such as
carburizing, slow cooling, and quenching by high-frequency
heating.
SUMMARY OF THE INVENTION
[0004] In the case of steel raw material with a high content (for
example, 0.2% by mass or more) of Cr as disclosed in the related
art, Cr carbide is formed in a pearlite structure and a ferrite
structure in a carburized layer when the steel raw material is
slowly cooled after being carburized. Then, the Cr carbide is
dissolved in a matrix by performing the high-frequency heating at a
relatively high temperature (for example, at 950.degree. C. or
higher) after the slow cooling. Consequently, austenite
transformation occurs uniformly during the high-frequency heating,
and thus a uniform quenched structure is obtained. As a result,
uniform hardness is also obtained. On the other hand, if the
high-frequency heating is performed at a relatively low temperature
(for example, at lower than 950.degree. C.) after the slow cooling,
the Cr carbide is hardly dissolved in the matrix. Consequently, the
austenite transformation occurs nonuniformly, causing the quenched
structure to be also nonuniform. This phenomenon serves as a factor
of occurrence of nonuniformity of hardness.
[0005] For the same reason, a high content (for example, 0.1% by
mass or more) of Mo also serves as a factor of occurrence of
nonuniformity of hardness, though not to the same extent as in the
case of Cr. This is because Mo also forms carbide during the slow
cooling after the carburizing. In other words, in order to obtain a
uniform quenched structure in the case of steel raw material with a
high content of Cr or Mo, the high-frequency heating after the slow
cooling needs to be performed at a relatively high temperature.
[0006] Here, when a steel member is used for a gear, a surface
layer portion thereof is required to have high hardness whereas an
inner layer portion thereof is required to have high toughness
rather than hardness. In addition, high shape accuracy is required.
In order to obtain both the high hardness of the surface layer
portion and the high toughness of the inner layer portion, it is
necessary to perform quenching by heating only the surface layer
portion of the gear in a profiling manner when applying induction
hardening. In order to achieve this, the induction hardening needs
to be performed with a high output in a short time. By suppressing
the heating time to be short, heat conduction to the inner layer
portion is suppressed so as to achieve the heating in a profiling
manner. Because the heating output is made high by a corresponding
amount, the surface layer portion is heated to a relatively high
temperature. Particularly, a tooth tip portion may almost melt.
[0007] By using the heating method as described above, it is
possible to obtain a uniform quenched structure in the surface
layer portion including the tooth tip because the Cr carbide or the
Mo carbide dissolves in the matrix as described above. Note that,
although a surface layer portion of a tooth root portion is
slightly lower in temperature (for example, at approximately
950.degree. C.) than that of the tooth tip portion, the temperature
is not low enough so as to produce nonuniformity of hardness. This
is because the high-frequency heating itself is performed with a
high output.
[0008] Some gears are used in a vehicle drive train system,
particularly for a differential ring gear, for transmitting very
high torque. In such a use, a stress is applied not only to the
surface layer portion of the gear, but also to the inside of the
gear. Therefore, the hardness is required not only of the surface
layer portion, but also of a deep layer portion lying deeper than
the surface layer portion. Consequently, not only the surface layer
portion, but also the deep layer portion, particularly the inside
of a tooth portion, needs to be increased in temperature to or
above an austenite transformation temperature during quenching
treatment. However, it is not appropriate to increase the
temperature of the entire gear to or above the austenite
transformation temperature. The reason for this is that, if the
entire gear is transformed into austenite, the shape accuracy
deteriorates because of volumetric expansion associated with
martensitic transformation during rapid cooling after the austenite
transformation. This causes problems such as occurrence of noise
when the gear is used.
[0009] Therefore, a portion in a somewhat thick range including the
surface layer and the deep layer portion therebelow is increased in
temperature to or above the austenite transformation temperature
without increasing the temperature of the inner layer portion of
the gear to or above the austenite transformation temperature. In
this case, the heat conduction from the surface layer to the deep
layer portion is actively used. Therefore, in contrast to the
above, the heating time needs to be long to a certain extent, and
the heating output results in being smaller by a corresponding
amount. As a result, the tooth tip portion is prevented from
overheating, thereby resulting in the heating with a relatively
good temperature distribution.
[0010] However, in this case, the following two problems occur.
First, the austenite transformation is made at a relatively low
temperature during the quenching treatment. Consequently, if the
content of Cr or Mo is high, some of the Cr carbide or the Mo
carbide may remain undissolved in the matrix even by heating during
the quenching treatment. This remnant carbide causes a loss in
hardness or nonuniformity of hardness.
[0011] Secondly, there is a problem in a place lying slightly
deeper than the surface layer portion. In the case of the
high-frequency heating, the temperature is lower in the deep place
than in the surface layer portion. Therefore, even in the range of
the carburized layer, the problem of the remnant carbide is more
likely to occur in the place deeper than the surface layer portion
than in the surface layer portion. In such a place, nonuniformity
of hardness is more likely to occur than in the surface layer
portion.
[0012] In view of the problems described above, it is an object of
the present invention to provide a gear that is free from
nonuniformity of hardness while having high hardness in the surface
layer portion and the deep layer portion thereof as well as high
shape accuracy, and to provide a manufacturing method of the
gear.
[0013] As described above, the present invention specializes in a
gear of a carburized steel member and a manufacturing method for
producing the gear through a carburizing process conducted under a
reduced pressure, a cooling process to perform slow cooling under
the particular conditions described above, and a quenching process
employing the heating by high-density energy. In the present
invention, the chemical composition within the above-specified
range is employed as an optimal chemical composition for producing
the gear by this manufacturing method. Points to be noted in the
above-specified chemical composition are that the contents of Cr
and Mo are confined within levels to be contained as impurities,
or, if added, are limited to less than 0.2% and 0.1% or less,
respectively.
[0014] Cr, when added at a concentration of less than 0.2%, is an
effective element for improving hardenability and for increasing
resistance to temper softening. On the other hand, if Cr is added
at a concentration of 0.2% or more, Cr carbide is formed in a
pearlite structure and a ferrite structure in a carburized layer
during the slow cooling after the carburizing treatment. The Cr
carbide, unless dissolved in a matrix during the subsequent
quenching process, produces a nonuniform quenched structure,
thereby causing occurrence of nonuniformity of hardness. However,
if the heating is performed in a very short time by using
high-density energy as in the present invention, it is difficult to
dissolve the Cr carbide in a solid state in the matrix.
[0015] Therefore, in the present invention, as described above, Cr
is actively treated as an optional component, and the content of
Cr, if contained, is limited to the concentration of less than
0.2%. As a result, the Cr carbide is prevented from being formed
during the slow cooling described above. Consequently, even if a
heating unit in the quenching process performs heating by using
high-density energy, the Cr carbide, if any present before the
heating, can be dissolved in a solid state in the matrix in a sure
manner, thus making it possible to reduce structural nonuniformity.
In addition, raw material cost can be reduced by reducing the
additive amount of expensive Cr.
[0016] Mo is an effective element for improving hardenability and
for increasing resistance to temper softening. However, in the
present invention, because the required hardenability is ensured by
adding appropriate amounts of Si and Mn (particularly Si), a
uniform martensitic structure can be obtained without relying on
the hardenability improvement effect by Mo. Accordingly, as
described above, by limiting the heating unit in the quenching
process to the heating by using high-density energy, the raw
material cost can be reduced while making it possible to improve
productivity of the carburizing treatment. If the content of Mo is
large, Mo carbide is formed. The Mo carbide can further worsen the
structural nonuniformity in combination with the structural
nonuniformity caused by Cr. Therefore, the additive concentration
of Mo is limited to 0.1% or less so as to obtain an effect to
reduce the structural nonuniformity.
[0017] In the gear of the present invention, the following effects
are obtained by the raw material steel and the manufacturing method
described above. First of all, it can be stated that grain boundary
oxidation is suppressed by performing the carburizing in a
carburizing atmosphere of a lower oxygen concentration than that of
the atmosphere. In addition, the effect of the quenching is exerted
not only on a surface layer (first quench-hardened layer), but also
on a portion therebelow (second quench-hardened layer). As a
result, the gear is achieved with entire tooth portions having high
strength. Furthermore, by performing the heating itself in the
quenching process in a relatively long time at a relatively low
temperature so as to make a deeper region than the second
quench-hardened layer to be an unquenched layer, distortion is
suppressed and fatigue strength is improved.
[0018] Therefore, the gear obtained by the present invention is
reduced in the nonuniformity of hardness by the reduction in the
structural nonuniformity, and provides excellent performance for
cost.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIG. 1 is a perspective view showing an overall shape of a
gear according to an embodiment;
[0020] FIG. 2 is an enlarged view of a part of the gear of FIG.
1;
[0021] FIG. 3 is a cross-sectional view showing a stress
distribution when the gear according to the embodiment is in
use;
[0022] FIG. 4 is a cross-sectional view showing a distribution of a
carburized layer and a quench-hardened layer in the gear according
to the embodiment;
[0023] FIG. 5 is an explanatory diagram showing a structure of heat
treatment equipment used in an example;
[0024] FIG. 6 shows a heat pattern of reduced-pressure carburizing
treatment and reduced-pressure slow cooling treatment;
[0025] FIG. 7 shows a heat pattern of a quenching process;
[0026] FIG. 8 is a temperature rise chart during a temperature
rising period of the quenching process;
[0027] FIG. 9 is another example of the heat pattern of the
quenching process;
[0028] FIG. 10 is a graph showing a relation between hardness and
depth after the quenching process; and
[0029] FIG. 11 is a drawing of another example of the gear to which
the present invention can be applied.
DETAILED DESCRIPTION OF THE EMBODIMENT
[0030] First of all, description will be made of reasons for
limiting the chemical composition of steel raw material used in the
present invention. Hereinafter, the unit "% by mass" in a
composition will be represented simply as "%".
[0031] C: 0.1% to 0.40%
[0032] C is an element that is added for ensuring strength,
particularly strength in a deep layer portion, of the steel raw
material. Therefore, in the present invention, the internal
strength is ensured by setting the lower limit of additive
concentration of C to 0.1%. However, if the additive concentration
of C exceeds 0.40%, the following two disadvantages occur. One is
that toughness is reduced while hardness is increased. The other is
that the machinability of the steel raw material deteriorates.
Therefore, the upper limit of additive concentration of C has been
determined to be 0.40%. A more preferable range of the additive
concentration is 0.15% to 0.3%.
[0033] Si: 0.35% to 3.0%
[0034] Si is an effective element not only for deoxidation in a
steel-making process, but also for providing strength and
hardenability necessary for the steel raw material as well as for
improving the resistance to temper softening. The present invention
is characterized by being capable of significantly reducing Cr and
Mo that are expensive. However, in the case of parts required to be
resistant to temper softening, such as a gear requiring pitting
strength, it may be disadvantageous to reduce Cr and Mo to be less
than those in Cr--Mo steel, which is a conventional steel type.
Therefore, in order to obtain the required resistance to temper
softening even when Cr and Mo are reduced, Si has been determined
to be contained at a concentration of 0.35% or more. However,
because this effect obtained by containing Si is saturated at a
content of approximately 3.0%, no positive advantage is obtained by
containing more Si. Not only that, an excess Si content of more
than 3.0% deteriorates machinability of the raw material by
bringing about an increase in the hardness thereof. Therefore, the
Si content needs to be in a range of 0.35% to 3.0%. A more
preferable range is from more than 0.45% to 1.5%.
[0035] In addition, if the steel raw material added with a large
amount of Si is used in the case of using oxidizing atmosphere gas
in a gas carburizing treatment, grain boundary oxidation occurs and
an abnormal carburized layer is produced in a surface layer during
the carburizing process. This is because Si is likely to form an
oxide. Consequently, the strength of a carburized layer is reduced,
leading to reduction in bending fatigue strength and contact
pressure fatigue strength. On the other hand, the present invention
employs a process in which the carburizing treatment is performed
in a carburizing atmosphere in which the oxygen concentration is
reduced by reducing pressure. As a result, the problem of the grain
boundary oxidation is eliminated as will be described later.
Therefore, the steel raw material with an actively increased Si
content can be used.
[0036] Mn: 0.1% to 3.0%
[0037] Mn is an effective element not only for deoxidation in a
steel-making process, but also for improving the hardenability.
However, when the content of Mn is less than 0.1%, the effect
thereof is insufficient. On the other hand, because the effect
obtained by containing Mn is saturated at a content of
approximately 3.0%, no positive advantage is obtained by containing
more Mn. Not only that, an excess Mn content of more than 3.0%
deteriorates machinability of the raw material by bringing about an
increase in the hardness thereof. Therefore, the Mn content needs
to be in a range of 0.1% to 3.0%. A more preferable range is from
0.5% to 1.5%.
[0038] P: 0.03% or less
[0039] P has an effect of reducing the toughness by being
segregated at grain boundaries in the steel. Therefore, P needs to
be reduced as much as possible, and needs to be limited to 0.03% or
less, though hardly possible to be zero.
[0040] S: 0.15% or less
[0041] S forms MnS in the steel, and is therefore an element added
for the purpose of improving machinability of the raw material by
MnS. However, because this effect obtained by containing S is
saturated at a content of approximately 0.15%, no positive
advantage is obtained by containing more S. Not only that, an
excess S content of more than 0.15% brings about grain boundary
embrittlement by causing grain boundary segregation. Therefore, the
S content needs to be 0.15% or less. Note that the machinability
improvement effect is not significant if the S amount is less than
0.001%. Therefore, the lower limit, if to be specified, is set to
0.001% or more. A more preferable range is a range of 0.005% to
0.06%.
[0042] Al: 0.05% or less
[0043] Al is precipitated and dispersed as a nitride in the steel.
This behavior makes Al to be an effective element for preventing an
austenitic structure from coarsening during the carburizing
treatment. However, an excess Al content of more than 0.05%
coarsens the precipitate, thereby embrittling the steel. Therefore,
the upper limit is set to 0.05%. Note that recrystallization occurs
in a portion to which the high-density energy quenching treatment
is applied so that the coarsened austenitic structure is made fine.
Therefore, it is not essential to contain Al if high strength is
required only in the portion to which the high-density energy
quenching treatment is applied, but not required in regions not
heated by high-density energy. However, if high strength is also
required in the regions not heated by high-density energy, Al needs
to be contained. In that case, the effect for prevention of
coarsening of the austenitic structure is insufficient when the Al
amount is less than 0.005%. Therefore, the lower limit, if to be
specified, is set to 0.005% or more. A more preferable range is
from 0.02% to 0.04%.
[0044] N: 0.03% or less
[0045] N has an effect of forming various nitrides so as to prevent
the austenitic structure from coarsening during the carburizing
treatment and during the high-density energy quenching treatment.
However, an excess N content of more than 0.03% significantly
worsens forgeability. Therefore, the upper limit is set to 0.03%.
Note that, for the same reason as the reason described in the
paragraph regarding Al, it is essential to contain N only when high
strength is also required in the regions not heated by high-density
energy. In that case, the effect for prevention of coarsening of
the austenitic structure is insufficient when the N amount is less
than 0.003%. Therefore, the lower limit, if to be specified, needs
to be set to 0.003% or more. A more preferable range is from 0.005%
to 0.02%.
[0046] Cr: less than 0.2%
[0047] Cr, when added at a concentration of less than 0.2%, is an
effective element for improving the hardenability and the
resistance to temper softening. However, if the additive
concentration of Cr is 0.2% or more, Cr carbide is formed in a
pearlite structure and a ferrite structure in the carburized layer
during slow cooling after the carburizing treatment. This
phenomenon significantly occurs particularly when the material has
a hypoeutectoid composition with a C concentration of 0.5% to less
than 0.8% during carburizing. The Cr carbide is dissolved in a
matrix by performing the heating by high-density energy at a
relatively high temperature (for example, at 950.degree. C. or
higher) after the slow cooling. Consequently, austenite
transformation occurs uniformly during the high-frequency heating,
and thus a uniform quenched structure is obtained. As a result,
uniform hardness is also obtained. On the other hand, if the
heating by high-density energy is performed at a relatively low
temperature (for example, at lower than 950.degree. C.) after the
slow cooling, the Cr carbide is hardly dissolved in the matrix.
Consequently, the austenite transformation occurs nonuniformly,
causing the quenched structure to be also nonuniform. This
phenomenon serves as a factor of occurrence of nonuniformity of
hardness. Therefore, when the C concentration during the
carburizing is in a range of 0.5% to less than 0.8%, it is
preferable to suppress the Cr amount to a minimum necessary value
so as to suppress the formation itself of the Cr carbide.
[0048] In addition, by limiting the Cr amount to the minimum
necessary value, the Cr carbide easily dissolves in the matrix when
a desired portion is heated by high-density energy into the
austenite region during the quenching process. Therefore, the input
energy during the high-density energy heating (integrated value of
heating temperature during a period in which the temperature is at
the transformation point or higher) can be reduced. As a result,
energy saving and cost reduction can be achieved in the quenching
process.
[0049] It is known that the formation of the Cr carbide can be
suppressed by a considerable degree by achieving a chemical
composition that satisfies the condition,
[Si %]+[Ni %]+[Cu %]-[Cr %]>0.5
[0050] even if the content of Cr is 0.2% or more. However,
satisfaction of this condition is not sufficient for suppressing
the nonuniformity of hardness. A more preferable range of the Cr
content is 0.1% or less. It should be noted that reduction in the
content of Cr serves as a factor for reducing the hardenability and
the resistance to temper softening. However, in the present
invention, as described above, the hardenability and the resistance
to temper softening are ensured by containing appropriate amounts
of Si and Mn. [0051] Mo: 0.1% or less
[0052] It is an object of the present invention to reduce Mo that
is a relatively expensive metal among minor metals. However, Mo may
be added if the added amount is extremely small. Mo is an effective
element for improving the hardenability and the resistance to
temper softening. However, containing of a large amount of Mo not
only increases cost, but also serves as a factor of occurrence of
nonuniformity of hardness for the same reason as in the case of Cr,
though not so significantly as in the case of Cr. This is because
Mo also forms a carbide during the slow cooling after the
carburizing. Therefore, the upper limit needs to be set to 0.1%. If
the hardenability and the resistance to temper softening that are
necessary can be ensured by other elements, it is preferable to
avoid adding Mo. In that case, it is advisable to set the upper
limit to less than 0.01%, which represents the condition that Mo is
not actively added. It should be noted that the reduction in the
content of Mo also serves as a factor for reducing the
hardenability and the resistance to temper softening in the same
manner as in the case of Cr. However, in the present invention, as
described above, this problem is dealt with by containing Si and
Mn.
[0053] The steel raw material used in the present invention may
further contain Ti: 0.005% to 0.2% and B: 0.0006% to 0.005%.
[0054] Ti: 0.005% to 0.2%
[0055] Ti is an element easily combined with N. Therefore, Ti has
an effect of preventing B from forming BN, and thereby, from losing
the hardenability improvement effect thereof. In addition, Ti is an
effective element for preventing the austenitic structure from
coarsening during the carburizing treatment and during an induction
hardening treatment because Ti is precipitated and dispersed as a
carbonitride in the steel. However, when the content of Ti is less
than 0.005%, the effect thereof is not significant. On the other
hand, an excess Ti content of more than 0.2% coarsens the
precipitate, thereby embrittling the steel. Therefore, the upper
limit has been determined to be 0.2%. The most preferable range of
the content of Ti is from 0.01% to 0.03%.
[0056] B: 0.0006% to 0.005%
[0057] B, when being added, is an effective element for providing
the hardenability and strengthening the grain boundaries. However,
when the content of B is less than 0.0006%, the effect thereof is
not significant. On the other hand, because this effect is
saturated at a content of approximately 0.005%, no positive
advantage is obtained by adding more B. Therefore, a preferable
range is from 0.0006% to 0.005%. The most preferable range is from
0.001% to 0.003%.
[0058] The steel raw material used in the present invention may
further contain either or both of Nb: 0.01% to 0.3% and V: 0.01% to
0.2%.
[0059] Nb: 0.01% to 0.3% and V: 0.01% to 0.2%
[0060] Nb and V are elements that are precipitated and dispersed as
a carbonitride in the steel. Therefore, Nb and V are effective for
preventing the austenitic structure from coarsening during the
carburizing treatment and during the induction hardening treatment.
However, when the content of each of Nb and V is less than 0.01%,
the effect thereof is not significant. On the other hand, too large
content coarsens the precipitate, thereby embrittling the steel.
Therefore, the upper limits have been determined to be 0.3% for Nb
and 0.2% for V. Most preferably, it is advisable to add Nb at a
content in a range of 0.01% to 0.02%, and V at a content in a range
of 0.01% to 0.05%.
[0061] The steel raw material used in the present invention can
further contain Ni: 0.1% to 3.0%.
[0062] Ni: 0.1% to 3.0%
[0063] Ni is an effective element for improving the toughness.
However, when the content of Ni is less than 0.1%, the effect
thereof is not significant. On the other hand, because the effect
is saturated at a content of approximately 3.0%, no positive
advantage is obtained by adding more Ni. Not only that, an excess
Ni content of more than 3.0% deteriorates machinability of the raw
material by bringing about an increase in the hardness thereof.
Therefore, the Ni content needs to be in a range of 0.1% to 3.0%.
The most preferable range is from 0.5% to 1.5%.
[0064] As shown in FIG. 1, a gear 8 according to a present
embodiment is provided with tooth portions 81 at even intervals on
the circumferential edge of a circular disk portion 82. Note that,
although the disk portion 82 shown in FIG. 1 is ring-shaped rather
than disk-shaped, such a portion is also included in the term
"disk". As shown in FIG. 2, each of the tooth portions 81 has a
tooth wall surface 811 and a tooth top surface 812. A corner-shaped
side between the tooth wall surface 811 and the tooth top surface
812 is referred to as a tooth tip corner portion 813. A tooth root
portion 815 lies between the tooth portion 81 and the tooth portion
81.
[0065] The gear 8 of the present embodiment is applied, for
example, to various gears in a vehicle drive train system. Gears of
the vehicle drive train system are subjected to strict requirements
such as low cost, high strength, and high shape accuracy. The
present invention is very effective in satisfying those
requirements. Gears in an automatic transmission and in a
differential gear are examples of the gears of the vehicle drive
train system.
[0066] When the gear 8 is used for such applications as described
above, a very large stress is applied to the tooth portions
thereof. This phenomenon will be described according to FIG. 3.
FIG. 3 shows a result of simulation of a stress distribution in a
cross section of the gear 8 when in use. FIG. 3 shows a state in
which a driving force is applied to the tooth wall surface 811 on
the right side of the tooth portion 81. In FIG. 3, regions 71 are
regions to which the largest stress is applied. The stress becomes
smaller in regions 72, 73, and 74, in this order.
[0067] As is seen in FIG. 3, it is found that there are two places
on which the stress concentrates when the gear is driven. One place
is near the boundary between the tooth wall surface 811 and the
tooth root portion 815. Mainly a bending stress is applied to this
place. Another place is near a position in the tooth wall surface
811, the position being located where the distance from the tooth
tip corner portion 813 is slightly smaller than the distance from
the tooth root portion 815. Mainly a shear stress is applied to
this place. In either of these two places, a large stress is
applied not only to the vicinity of a surface layer of the gear 8,
but also to a considerably deep portion. Even the regions 71 alone
are deeper than the depth of a general carburized layer. Therefore,
the gear 8 used for such applications as described above is
required to have not only high surface hardness in the tooth
portions 81, but also toughness inside the tooth portions 81.
[0068] The raw material of the gear 8 of the present embodiment is
a hot-rolled steel product having the chemical composition within
the above-specified range. This raw material is used as starting
material, and roughly formed by hot forging. Then, anneal treatment
is applied, and further, the tooth portions 81 are formed by
cutting work. Through these processes, an outer shape of the gear 8
is completed. However, in addition to the above processes, the
following treatment processes are further applied to the gear 8 of
the present embodiment.
[0069] 1. Carburizing Process
[0070] This is a process to apply treatment for forming the
carburized layer in the surface layer portion of the gear 8 by
heating the gear 8 in the carburizing atmosphere.
[0071] 2. Cooling Process
[0072] This is a process to cool the gear 8 after the carburizing
process. This cooling needs to be performed at least until the
structural transformation by temperature drop after the carburizing
is performed is completed.
[0073] 3. Quenching Process
[0074] This is a process to locally heat the gear 8 after the
cooling process into the austenite region by high-density energy,
and after the heating, to rapidly cool and harden the gear 8.
[0075] The carburizing process described in "1" above will be
further explained. First of all, the carburizing process is
performed in carburizing gas under a pressure reduced to below the
atmospheric pressure; that is, the process is a reduced-pressure
carburizing process. In the reduced-pressure carburizing process,
it is possible to perform the carburizing treatment with a
relatively small amount of carburizing gas while maintaining in a
reduced pressure state the inside of a carburizing furnace under a
high temperature. Therefore, the carburizing treatment can be
performed more efficiently than conventionally possible. In
addition, there is no need to perform long-time heating treatment,
as is required when a conventional large-size heat-treating furnace
is used. Therefore, treatment time and energy consumption can be
reduced, and furthermore, carburizing and quenching equipment
itself can be downsized.
[0076] When the reduced-pressure carburizing process is applied,
the present invention effectively exerts the effect of treating Cr
as an optional component that is not actively added, and of
limiting the upper limit value of Cr. In other words, because
ordinary gas carburizing is performed through an equilibrium
reaction, conditions can be set by calculating a carbon potential
in advance. However, because the reduced-pressure carburizing
treatment is a nonequilibrium reaction, it is difficult to set the
conditions by such a calculation. In addition, when a steel member,
such as a gear, having projected and depressed portions is
processed by the reduced-pressure carburizing treatment, the rate
of diffusion of carbon that has infiltrated differs depending on
the portion. As a result, the obtained carbon concentration of the
surface varies depending on the portion. In other words,
nonuniformity of carburizing occurs. As a result, in some cases, a
desired effect of modification is not obtained at a portion to be
given a surface modification by the carburizing treatment.
[0077] If the Cr content of the raw material steel is large, the
above-described formation of the Cr carbide can develop
significantly in the case in which, as described above, a larger
variation in degree of carburizing occurs than in the case of
ordinary gas carburizing. In the present invention, because the Cr
content is suppressed to be small, the formation of the Cr carbide
as described above is suppressed. In this regard, the effect of
limiting Cr is particularly effective because the reduced-pressure
carburizing process is employed.
[0078] Because the reduced-pressure carburizing is employed, the
pressure of the carburizing atmosphere during the carburizing
process is lower than the atmospheric pressure. Accordingly, the
oxygen concentration in the ambient atmosphere can be suppressed to
be low. As a result, the grain boundary oxidation in the carburized
layer can be prevented. Note that there is also a method for
suppressing the amount of oxygen in the ambient atmosphere to be
low by filling nitrogen gas or inert gas without reducing the
pressure. The grain boundary oxidation in the carburized layer can
also be prevented by such a method.
[0079] Note that the carburizing generally refers to treatment in
which hydrocarbon-based gas (carburizing gas such as methane,
propane, ethylene, or acetylene) is directly introduced into a
furnace, and then steel material to be treated (here, the gear 8)
is placed in the furnace atmosphere and heated so as to infiltrate
carbon the surface layer of the steel material to be treated,
thereby forming a carburized layer. In this carburizing treatment,
first, during a carburizing period, molecules of the carburizing
gas contact the surface of the steel, and decompose to produce
active carbon. This active carbon is supplied to the surface of the
steel to form the carbide. As a result, the carbon is stored on the
surface of the steel.
[0080] During the subsequent diffusion period, the carbide
decomposes, and the stored carbon dissolves into the matrix. As a
result, the carbon diffuses toward the inside to form the
carburized layer. The infiltration route of the carbon is not
limited to a route via the carbide, but there is also a route along
which the active carbon directly dissolves into the matrix.
[0081] The ambient pressure during the reduced-pressure carburizing
process is preferably in a range of 1 hPa to 100 hPa. If the
ambient pressure during the reduced-pressure carburizing process is
reduced to less than 1 hPa, expensive equipment is required to
achieve and maintain an appropriate degree of vacuum. On the other
hand, if the ambient pressure is a high pressure exceeding 100 hPa,
soot is produced during the carburizing. As a result, a problem can
occur in which the nonuniformity of carburizing occurs. The
hydrocarbon-based gas such as acetylene, propane, butane, methane,
ethylene, or ethane can be applied as the carburizing gas.
[0082] It is preferable to perform the carburizing process under
the conditions under which the carbon concentration of the surface
of the steel material after the diffusion period is 0.85% or less.
In this way, the amount of carbon in the carburized layer is made
to be equal to or less than that of eutectoid steel. Therefore, by
effecting the austenite transformation by heating during the later
quenching process, and then by performing the rapid cooling, the
martensitic structure can be formed without precipitating
cementite.
[0083] The gear of the present embodiment includes a first portion
and a second portion with different diffusion rates of carbon
having infiltrated during the carburizing treatment because of
their shapes. The diffusion rate of carbon having infiltrated is
lower in the second portion (difficult carbon diffusion portion)
than in the first portion (easy carbon diffusion portion). It is
preferable to perform the carburizing process under the conditions
under which the carbon concentration of the surface of the first
portion is in a range of 0.65%.+-.0.1%. Here, in FIG. 3, the tooth
wall surface 811, the tooth root portion 815, and the tooth top
surface 812 (not including the tooth tip corner portion 813)
correspond to the first portion, whereas the tooth tip corner
portion 813 corresponds to the second portion.
[0084] As described above, the reduced-pressure carburizing
treatment is a nonequilibrium reaction. Therefore, when the steel
member, such as the gear 8, having projected and depressed portions
is processed by the reduced-pressure carburizing treatment, the
rate of diffusion of the carbon having infiltrated differs
depending on the portion. Consequently, it has been found that the
obtained carbon concentration of the surface varies depending on
the portion, and that, in some cases, a desired effect of
modification is not obtained at a portion to be given the surface
modification by the carburizing treatment.
[0085] Note that, because the reduced-pressure carburizing
treatment is a nonequilibrium reaction, the obtained carbon
concentration of the surface differs between immediately after the
carburizing period for carrying out the carburizing and after the
diffusion period for carrying out the diffusion of the carbon that
has infiltrated to the inside thereafter. The carbon concentrations
of the carburized layer described above are represented by using
the values obtained after the diffusion period without exception.
Consequently, all of the carbon concentrations of the carburized
layer in the present specification represent values of the carbon
concentrations obtained not immediately after the carburizing
period but after the diffusion period (the same applies
hereinafter).
[0086] In view of such a situation, it has been found that the
optimal conditions for the case in which the reduced-pressure
carburizing process is applied to the gear 8 that has, because of
the shape thereof, the first portion (easy carbon diffusion
portion) and the second portion (difficult carbon diffusion
portion) are conditions under which the carbon concentration of the
surface of the first portion is in a range of 0.65%.+-.0.1% as
described above.
[0087] By performing the reduced-pressure carburizing treatment
under the condition as described above, the inventor of the present
invention has found for the first time as a result of many
experiments that the obtained carbon concentration of the surface
of the second portion, that is, the portion in which the rate of
diffusion is lower than that of the first portion and the surface
carbon concentration after the carburizing treatment is higher than
that of the first portion, in the gear 8 can be suppressed in a
range of less than 0.85%.
[0088] As a result, it is possible to limit within a range of 0.60%
to 0.85% the carbon concentration of almost entire surface of the
portion to be given the surface modification by the carburizing
treatment of the gear 8. By limiting the surface carbon
concentration in this range, and then, by further applying a
special quenching process in which the gear 8 is rapidly cooled
after being heated by using high-density energy, a quenching effect
is sufficiently obtained even in the portion (first portion) in
which the surface carbon concentration is near the lower limit, and
a trouble caused by excessive carbon can be suppressed in the
portion (second portion) in which the surface carbon concentration
is near the upper limit. Thus, an excellent modified surface is
obtained after the quenching.
[0089] When performing the reduced-pressure carburizing treatment
under the carburizing conditions described above, it is necessary
to adjust conditions such as temperature, type of carburizing gas,
pressure, and treatment time in the reduced-pressure carburizing
treatment process so that the carbon concentration of the surface
of the first portion falls in the above-described particular range.
For that purpose, it is desirable to find appropriate conditions by
conducting a plurality of preliminary experiments with these
conditions variously changed, and then, to perform the
reduced-pressure carburizing treatment under the conditions thus
found. Note that, if each gear 8 serving as a piece of material to
be processed has the same shape, the times of the preliminary
experiments can be reduced by accumulation of data. When
determining the first portion and the second portion in the gear 8,
it is possible to make a judgment by actually measuring carbon
concentrations at a plurality of places in the preliminary
experiments. The determination may be made by observing the shape
because the judgment can be made relatively easily based on the
shape.
[0090] Through the carburizing process as described above, a
carburized layer 91 shown in the cross-sectional view of FIG. 4 is
formed in which the carbon concentration is higher than the carbon
concentration of the steel. In other words, the carbon supplied to
the surface of the steel infiltrates from the surface to the inside
by diffusion, whereby the carburized layer 91 is formed in the
surface layer portion. The carbon concentration in the carburized
layer is made to be in a range of 0.60% to 0.85% on the surface as
described above, and is gradually reduced toward the inside until
reaching the carbon concentration of the raw material steel. The
carburized layer 91 is formed in the surface layer of the tooth
portion 81 and the tooth root portion 815. The thickness of the
carburized layer 91 is approximately 0.7 to 1.3 mm. Note that FIG.
4 is drawn in such a manner that a quench-hardened layer 92 is
present below the carburized layer 91. However, the quench-hardened
layer 92 is formed after the completion of the quenching process to
be described later. Therefore, the quench-hardened layer 92 has not
yet been formed at this stage.
[0091] Next, the cooling process described in "2" above will be
explained. The cooling process is performed under slow cooling
conditions. More specifically, the gear 8 is cooled, at least at a
lower cooling rate than a cooling rate at which the steel material
of the gear 8 is transformed into martensite, to or below a
temperature at which structural transformation by cooling is
completed. As a result, distortion associated with the martensitic
transformation can be prevented from occurring. Accordingly, the
carburizing treatment can be completed with excellent shape
accuracy.
[0092] Still more specifically, at least while the temperature of
the gear 8 is at or above the A1 transformation point of the raw
material steel thereof, it is preferable to cool the gear 8 at a
cooling rate in a range of 0.1.degree. C./s to 3.0.degree. C./s. If
the cooling rate exceeds 3.0.degree. C./s before the temperature of
the gear 8 drops below the A1 transformation point, a distortion
occurrence suppression effect during the cooling may not be
obtained sufficiently. On the other hand, if the cooling rate in
the cooling process becomes lower than 0.1.degree. C./s in the
period in which the temperature of the steel member is at or above
the A1 transformation point, the time required for the temperature
to drop below the A1 transformation point results in being long.
This result means that the carbon that has infiltrated into the
carburized layer by the carburizing diffuses toward entire steel
material during that time. Moreover, because the temperature during
the cooling differs depending on the portion in the gear 8, the
degree of diffusion also varies depending on the portion. As a
result, the carbon concentration varies depending on the
portion.
[0093] It is also preferable to perform the cooling process in a
cooling atmosphere at a pressure reduced to less than the
atmospheric pressure. In other words, the process is preferably a
reduced-pressure cooling process. With this process, the distortion
occurrence during the cooling can be further suppressed. The reason
for this is that the heat exchange rate between the steel material
and the ambient atmosphere can be reduced. Because of heat exchange
between the steel material and the ambient atmosphere, the ambient
temperature differs between the upstream side and the downstream
side of the wind flow in the ambient atmosphere, and the ambient
temperature in the downstream position is higher. When the pressure
of the ambient atmosphere is as high as the atmospheric pressure,
this temperature difference is significant because the heat
exchange rate is high. Accordingly, temperature differences occur
among portions in the gear 8, thereby producing a thermal
distortion.
[0094] On the other hand, by employing the reduced-pressure cooling
process, an essentially low heat exchange rate is obtained. As a
result, the temperature difference is small between the upstream
side and the downstream side of the wind, resulting in a
progression of relatively uniform cooling. Accordingly, the thermal
distortion is suppressed. Even in the case of cooling in a windless
state, the thermal distortion is smaller in the reduced-pressure
cooling than in the cooling at the atmospheric pressure. This is
because only a small difference in the cooling rate is produced by
stagnation of the cooling atmosphere of uneven temperature.
[0095] By such an effect of the reduced-pressure cooling process,
the distortion during the cooling after the carburizing can be
suppressed. As a result, it is possible to proceed to the next
process, that is, the quenching process, while maintaining high
dimensional accuracy. This effect is obtained in the highest degree
by performing the cooling process at a reduced pressure and in a
slowly cooling manner. In addition, the effect allows the gear 8
after the quenching to have high shape accuracy with little
distortion in combination with the advantage achieved by performing
the subsequent quenching process by the high-density energy
heating.
[0096] If both of the carburizing process and the cooling process
are performed under reduced pressures, the pressure difference
between both processes is small. Consequently, in the actual
equipment, both processes can be performed continuously by directly
connecting a carburizing chamber to a slow cooling chamber. This
means that an auxiliary chamber or the like for pressure adjustment
need not be provided between both chambers. In other words, a
product after completion of the reduced-pressure carburizing
treatment can be subjected to the reduced-pressure slow cooling
treatment without being exposed to the atmospheric pressure
condition. This feature also contributes to the reduction in the
distortion.
[0097] The ambient pressure in the cooling process is preferable to
be specifically in a range of 100 hPa to 650 hPa. If the pressure
during the cooling is higher than 650 hPa, the effect by pressure
reduction is insufficient. On the other hand, it is difficult to
reduce the pressure to lower than 100 hPa from the viewpoint of
equipment structure. A more preferable range of the pressure during
the cooling is from 100 hPa to 300 hPa.
[0098] Subsequently, the quenching process described in "3" above
will be explained. It is important in the quenching process to
partially heat a desired portion in the gear 8 to or above the
austenitizing temperature, and during the subsequent rapid cooling,
to transform at least the portion of the carburized layer into
martensite. Therefore, the heating needs to be performed by the
high-density energy heating. In addition, the rapid cooling needs
to be performed at or above a critical cooling rate for the
martensitic transformation. Examples of the high-density energy
heating include heating by irradiation of a high-density energy
beam such as an electron beam or a laser beam. The high-density
energy heating also includes the high-frequency heating as an
example other than the beam irradiation methods. Use of the
high-density energy heating shortens a heating time. In the present
embodiment, in combination with use of a low-Cr steel type that can
be easily austenitized, the high-density energy heating can harden
the gear 8 in a sure and sufficient manner.
[0099] The most preferable heating method for the high-density
energy heating is the high-frequency heating. The high-frequency
heating can accurately heat a desired portion with induction
heating in a noncontact manner, as well as in a highly efficient
manner. A known method can be used as a method of the
high-frequency heating itself.
[0100] The rapid cooling in the quenching process is preferable to
be performed by water cooling. In other words, because the heating
before the rapid cooling has been performed by the high-density
energy heating and not by any other method such as gas heating,
quenching distortion hardly occurs even if the water cooling of a
very high cooling rate is applied after the heating. This is
because the high-density energy heating can accurately heat the
gear 8 not entirely but partially. A high degree of quenching
effect is obtained by the superior rapid cooling by water cooling.
In other words, further high strength of a quenched portion is
achieved. The high degree of quenching effect makes it possible to
ensure required strength in some cases even if the carburizing
treatment is simplified, that is, even if the carburizing time is
shortened, or in other words, even if the carburized layer is
thinned. In this case, the time for an entire heat treatment
process can be further shortened.
[0101] When heating the gear 8 by the high-frequency heating, it is
preferable to process the gear 8 one by one. In addition, when the
gear 8 is cooled by water after heating, it is preferable to cool
the gear 8 by spraying cooling water to the gear 8 from its
periphery while rotating the gear 8. This makes it possible to
rapidly cool the gear 8 in a uniform manner. As a result, the
distortion is prevented from occurring during the rapid
cooling.
[0102] The high-density energy heating in the quenching process is
performed under the conditions under which the surface of the gear
8 is not melted, and a portion ranging from the surface to a
relatively large depth is austenitized. This purpose can be
achieved by supplying relatively small input energy for the
high-density energy heating, and as a compensation therefor, by
taking a slightly longer heating time (for example, approximately
15 to 25 seconds). In other words, the heating target temperature
is set to a temperature in a relatively low temperature range (for
example, 750.degree. C. to 960.degree. C.) of the austenite region
of the steel raw material, and the heating is performed for a
period of time slightly longer by a corresponding amount. This
makes it possible to heat all of a slightly thick region with a
depth exceeding 2 to 5 mm by heat conduction from the surface. As a
result, the quenching effect can be provided not only to the region
of the carburized layer but also to a region lying deeper than the
carburized layer. Because the austenitizing by the high-density
energy heating is achieved at a temperature confined in a
relatively low range, there is also an effect that the distortion
is suppressed during the water cooling after the heating.
[0103] Note that, when the heating is performed for a relatively
long time at a relatively low temperature as described above, the
nonuniformity of hardness may occur as described above unless the
Cr content is limited within the range specified in the present
invention. For this reason, also from the viewpoint of prevention
of the nonuniformity of hardness, it is beneficial that the Cr
content is limited to be low in the present invention.
[0104] In the present embodiment, the gear 8 serves as an object to
be processed. When the object to be processed is an object, such as
the gear 8, that has the projecting tooth portions 81, it is
preferable to perform the high-density energy heating under the
conditions under which all of the surface and the inside of the
tooth portions 81 are austenitized. This is because the gear 8 is
required to have both the high surface hardness of the tooth
portions 81 and the high toughness of the inside thereof. In
addition, the gear 8 is required to be such that the tooth portions
81 have the high shape accuracy. Therefore, as described above, it
is effective to perform the heating in the quenching process for a
relatively long time at a relatively low temperature. This is
because the quenching effect is exerted not only on the portion of
the carburized layer but also on the entire tooth portions 81, and
also because the high shape accuracy is obtained by suppressing the
distortion.
[0105] Thus, the quench-hardened layer 92 as shown in FIG. 4 is
formed. In FIG. 4, the quench-hardened layer 92 lies below the
carburized layer 91 in the surface layer of the gear 8.
Particularly, the inside of the tooth portion 81 entirely serves as
the quench-hardened layer 92. In addition, in the disk portion 82,
a portion below the carburized layer 91 in the surface layer of the
tooth root portion 815 and a portion below the tooth portion 81
serve as the quench-hardened layer 92. At a portion in the position
of the tooth root portion 815, the total thickness of the
carburized layer 91 and the quench-hardened layer 92 is
approximately 2 to 5 mm. As described above, the quench-hardened
layer 92 includes the martensitic structure. As a matter of course,
the carburized layer 91 that is given the effect of quenching
includes the martensitic structure. In the claims relating to the
gear, the carburized layer 91 is referred to as a "first
quench-hardened layer", and the quench-hardened layer 92 is
referred to as a "second quench-hardened layer".
[0106] All of the regions indicated as the regions 71, 72, and 73
in FIG. 3 serve as the carburized layer 91 or the quench-hardened
layer 92 in FIG. 4. In other words, the effect of quenching is
exerted on all of the regions on which the stress concentrates when
the gear is driven, and the hardness of the regions is increased.
Thus, it is realized to have both the high surface hardness of the
tooth portions 81 and the high toughness of the inside thereof.
[0107] An unquenched layer 93 lies below the quench-hardened layer
92. The unquenched layer 93 includes no martensitic structure. This
is because the unquenched layer 93 is a portion in which the
temperature has not increased to the austenitizing temperature
during the heating in the quenching process. Note that, as
described above, the C concentration of the surface in the
carburized layer 91 is made to be in a range of 0.60% to 0.85% by
the carburizing. The C concentration is gradually reduced toward
the inside until reaching the original C concentration of the steel
raw material. On the other hand, the C concentration of the
quench-hardened layer 92 and the unquenched layer 93 coincides with
the original C concentration of the steel raw material, which is in
a range of 0.1% to 0.40%. In the claims relating to the
manufacturing method of the gear, a portion to serve as the
unquenched layer 93 is referred to as a "core portion".
[0108] As described above, the heat treatment including the
carburizing process, the cooling process, and the quenching process
of the present invention is a treating method that prevents the
distortion from occurring. In other words, in the cooling process
after the carburizing, the gear 8 is cooled at a lower cooling rate
than the cooling rate at which the martensitic transformation
occurs. As a result, in both of the carburized layer and the core
portion lying deeper than the carburized layer, the martensitic
structure is not formed, but any of a ferrite, a pearlite, or a
bainite structure, or a mixed structure thereof is formed.
Therefore, the cooling in the cooling process does not produce a
martensitic transformation distortion, thus not deteriorating the
shape accuracy of the gear 8.
[0109] In addition the high-density energy heating is used for
heating in the quenching process after the cooling process. With
this heating method, heating can be applied to only a region of a
desired depth from the surface in a desired portion of the gear 8.
In other words, heating can be applied to only a region of a very
small volume relative to the entire volume of the gear 8. As a
result, not the whole but a partial range of the gear 8 is
transformed into martensite during the rapid cooling after the
heating. Consequently, the martensitic transformation distortion is
reduced, resulting in the high shape accuracy after the
quenching.
Example
[0110] Specific description will be made below of the gear and the
manufacturing method thereof in an example according to the present
invention and comparative examples thereof. These invention
examples are provided for the purpose of explaining the present
invention, and do not limit the scope of the present invention.
TABLE-US-00001 TABLE 1 Test Chemical Composition (% by mass) No. C
Si Mn Cr P S Al N Ti, B, Nb, V, Ni, Mo Invention Example 1 0.25
0.65 1.25 0.11 0.013 0.019 0.032 0.0054 -- 2 0.36 0.51 1.59 0.09
0.017 0.016 0.031 0.0125 -- 3 0.21 0.81 0.81 0.12 0.015 0.012 0.032
0.0038 0.015 (Ti), 0.0019 (B) 4 0.15 0.75 1.00 0.12 0.016 0.016
0.013 0.0038 0.031 (Ti), 0.0031 (B) 5 0.10 0.81 0.82 0.11 0.015
0.001 0.033 0.0038 -- 6 0.40 0.81 0.83 0.03 0.014 0.015 0.033
0.0040 0.030 (Ti), 0.0019 (B) 7 0.35 0.36 0.60 0.10 0.015 0.055
0.029 0.0040 -- 8 0.20 2.98 0.91 0.10 0.014 0.005 0.031 0.0041 -- 9
0.21 0.81 0.10 0.05 0.015 0.015 0.031 0.0040 -- 10 0.20 0.80 2.99
0.10 0.015 0.149 0.030 0.0038 -- 11 0.38 1.49 0.83 -- 0.015 0.015
0.030 0.0037 -- 12 0.20 0.51 1.10 0.19 0.015 0.011 0.033 0.0040 --
13 0.20 0.80 0.82 0.11 0.030 0.015 0.033 0.0041 -- 14 0.19 0.50
1.49 0.10 0.015 0.014 0.005 0.0041 -- 15 0.30 0.80 0.82 0.10 0.015
0.014 0.049 0.0040 -- 16 0.20 1.30 1.20 0.10 0.014 0.014 0.030
0.0038 0.005 (Ti), 0.0006 (B) 17 0.19 0.45 0.82 0.07 0.015 0.008
0.032 0.0042 0.190 (Ti), 0.0049 (B) 18 0.20 0.80 0.81 0.10 0.015
0.009 0.029 0.0031 -- 19 0.37 0.80 0.83 0.10 0.014 0.015 0.034
0.0296 -- 20 0.19 0.91 0.81 0.11 0.015 0.014 0.030 0.0040 0.015
(Nb) 21 0.20 0.81 1.21 0.10 0.016 0.015 0.031 0.0041 0.04 (V) 22
0.20 0.37 0.83 0.10 0.015 0.014 0.030 0.0040 1.01 (Ni) 23 0.20 0.80
0.71 0.10 0.014 0.015 0.033 0.0037 0.06 (Mo)
TABLE-US-00002 TABLE 2 Test Chemical Composition (% by mass) No. C
Si Mn Cr P S Al N Ti, B, Nb, V, Ni, Mo Comparative Example 24 0.21
0.79 0.10 0.015 0.014 0.030 0.0056 0.015 (Ti), 0.0021 (B) 25 0.79
0.83 0.10 0.015 0.060 0.033 0.0039 -- 26 0.20 0.50 0.83 0.015 0.015
0.030 0.0041 -- 27 0.21 0.91 0.66 0.016 0.019 0.030 0.0120 -- 28
0.30 0.80 0.82 0.015 0.015 0.029 0.0043 0.015 (Ti), 0.0015 (B) 29
0.20 0.79 1.10 0.10 0.015 0.032 0.0039 -- 30 0.32 1.29 0.60 0.08
0.013 0.033 0.0045 -- 31 0.20 0.81 0.015 0.015 0.033 0.0081 (Mo) 32
0.21 0.34 0.79 0.015 0.014 0.031 0.0078 (Mo)
[0111] In the present example, hot-rolled steel products having
chemical compositions shown in Table 1 (invention examples, Test
Nos. 1 to 23) and Table 2 (comparative examples, Test Nos. 24 to
32) were used as raw material to produce the gear 8 (differential
ring gear) by machining. This machining was used as a test (cutting
test) for judging the machinability of steel raw material. The
chemical composition of each raw material type of the comparative
examples of Table 2 is outside of the scope of the present
invention at each data point indicated in bold italic characters,
as described below.
[0112] In Test No. 24, Si is deficient.
[0113] In Test No. 25, C is excessive.
[0114] In Test Nos. 26 to 28, Cr is excessive.
[0115] In Test No. 29, P is excessive.
[0116] In Test No. 30, S is excessive.
[0117] In Test No. 31, Si is deficient, and Cr and Mo are
excessive.
[0118] In Test No. 32, Cr and Mo are excessive.
[0119] Among the above-described comparative examples, Test Nos. 31
and 32 are examples in which a conventional steel type, JIS-SCM420
(chromium-molybdenum steel), was used as raw material.
[0120] Subsequently, the carburizing process, then the cooling
process, and then the quenching process were applied to the gear 8
after the machining process. The gear 8 after these processes was
subjected to material quality examination and fatigue test.
[0121] Here, in the present example, brief description will be made
of heat treatment equipment that was used for performing a process
sequence from the carburizing process to the quenching process. As
shown in FIG. 5, the heat treatment equipment 5 used in the present
example has a pre-cleaning bath 51, a reduced-pressure carburizing
slow cooling apparatus 52, an induction hardening machine 53, and a
magnetic flaw detection apparatus 54. The pre-cleaning bath 51 is a
section in which the gear 8 is cleaned before the heat treatment is
started. The reduced-pressure carburizing slow cooling apparatus 52
is provided with a heating chamber 521, a reduced-pressure
carburizing chamber 522, and a reduced-pressure slow cooling
chamber 523. The gear 8 is increased in temperature in the heating
chamber 521. Then, the reduced-pressure carburizing is applied in
the reduced-pressure carburizing chamber 522, and the
reduced-pressure slow cooling is applied in the reduced-pressure
slow cooling chamber 523. No auxiliary chamber is provided between
the reduced-pressure carburizing chamber 522 and the
reduced-pressure slow cooling chamber 523. The induction hardening
machine 53 is a section in which the high-frequency heating and the
subsequent water cooling are applied to the gear 8 after the
reduced-pressure slow cooling. The magnetic flaw detection
apparatus 54 is a section in which a defect inspection is applied
to the gear 8 after the quenching.
[0122] Subsequently, description will be made of the processes that
were performed in the heat treatment equipment 5 shown in FIG. 5.
First, description will be made of the reduced-pressure carburizing
process performed in the reduced-pressure carburizing chamber 522
of the reduced-pressure carburizing slow cooling apparatus 52. As
described above, the carburizing treatment in the present example
is the reduced-pressure carburizing treatment that is performed in
the carburizing gas at a pressure reduced to less than the
atmospheric pressure. FIG. 6 shows a heat pattern in the
reduced-pressure carburizing treatment and the subsequent
reduced-pressure slow cooling treatment. In FIG. 6, the horizontal
axis represents the time, and the vertical axis represents the
temperature.
[0123] In FIG. 6, the symbol "a" represents a heating period in the
heating chamber 521. The symbols "b1" and "b2" represent holding
periods in the reduced-pressure carburizing chamber 522. An earlier
period "b1" of the holding periods corresponds to the carburizing
period in the carburizing treatment, and a subsequent later period
"b2" corresponds to the diffusion period in the carburizing
treatment. In the present example, a carburizing temperature, that
is, a holding temperature in the holding periods "b1" and "b2" was
set to 950.degree. C. that is a temperature at or above the
austenitizing temperature of the steel raw material. The
temperature of the gear 8 was increased to the holding temperature
in the heating period "a". The temperature of the gear 8 was
maintained to be a constant temperature, that is, the holding
temperature, during the holding periods "b1" and "b2".
[0124] In the present example, the pressure of the carburizing gas
in the reduced-pressure carburizing treatment was set to be in a
range of 1 hPa to 3.5. Acetylene was used as the carburizing gas in
the carburizing period "b1". The carburizing conditions were
determined as follows through the preliminary experiments conducted
in advance. Specifically, the gear 8 of the present example is a
differential ring gear, and, because of the shape thereof, has the
first portion (easy carbon diffusion portion) and the second
portion (difficult carbon diffusion portion). In the gear 8, as
shown in FIG. 2, the tooth root portion 815 and the tooth wall
surface 811 correspond to the first portion, and the tooth tip
corner portion 813 corresponds to the second portion. In the
present example, conditions were employed under which the carbon
concentration of the surface layer of the tooth root portion 815
corresponding to the first portion is in a range of
0.65%.+-.0.05%.
[0125] Subsequently, description will be made of the
reduced-pressure slow cooling process performed in the
reduced-pressure slow cooling chamber 523 subsequent to the
reduced-pressure carburizing treatment. As described above, the
slow cooling treatment in the present example is the
reduced-pressure slow cooling treatment that is performed in an
atmosphere at a pressure reduced to less than the atmospheric
pressure. In FIG. 6, a period represented by "c" is a slow cooling
period. In the present example, the ambient pressure in the
reduced-pressure slow cooling treatment was set to 600 hPa. The
type of the atmosphere gas is N.sub.2 gas. The cooling rate in the
reduced-pressure slow cooling treatment was set to be in a range of
0.1.degree. C./s to 3.0.degree. C./s. The cooling was performed at
this cooling rate until the temperature drops from a temperature at
or above the austenitizing temperature immediately after the
carburizing treatment to 150.degree. C. that is lower than the A1
transformation point. Note that the heat pattern shown in FIG. 6 is
an example, and can be changed, by conducting appropriate
preliminary tests, to a heat pattern of optimal conditions for the
type of steel raw material used.
[0126] Subsequently, description will be made of the quenching
process performed in the induction hardening machine 53. In the
quenching process of the present example, the high-frequency
heating was used as a unit to perform high-density energy heating.
The water cooling was used as a rapid cooling unit. FIG. 7 shows a
heat pattern of the quenching process of the present example. In
FIG. 7, in the same manner as in FIG. 6, the horizontal axis
represents the time, and the vertical axis represents the
temperature. In FIG. 7, the symbol "d1" represents a temperature
rising period, and the symbol "d2" represents a rapid cooling
period. In the temperature rising period "d1", the high-frequency
heating heats the tooth portions 81 on the outer circumferential
side of the gear 8 to a temperature at or above the austenitizing
temperature. In the subsequent rapid cooling period "d2", the
spraying of water rapidly cools the gear 8 so that the cooling rate
of the carburized layer thereof is equal to or higher than the
critical cooling rate. As described above, the critical cooling
rate refers to a cooling rate required for transforming into
martensite the austenitized steel raw material, particularly the
carburized layer portion thereof.
[0127] In the high-frequency heating during the temperature rising
period "d1", the amount of input energy was set to be smaller than
an amount given under conditions for ordinary high-frequency
heating, and the heating time was made relatively longer by a
corresponding amount to be 15 to 25 seconds. In this way, the whole
of the tooth portions 81 including not only the surface and the
vicinity thereof but also the inside was heated to be in a range of
750.degree. C. to 960.degree. C. The attained temperature on the
surface of the tooth root portion 815 was in a range of 920.degree.
C. to 940.degree. C. FIG. 8 is a temperature rise chart showing
actual temperatures on the surface of the tooth root portion 815
during the temperature rising period "d1". FIG. 8 shows measurement
results at three portions of a first end portion Rr, a middle
portion Mid, and a second end portion Fr located with respect to
the width direction of the gear 8. It is found that the
temperatures of all of the three portions increased into a range of
920.degree. C. to 940.degree. C. even in the period of 15 to 25
seconds after the temperature rise had started. Note that the
temperature rising rates are found to vary depending on the
position in the width direction while the temperatures are still
rising. This phenomenon is considered to occur because of
positional relationships relative to heating coils during heating.
However, there is no large difference in the time to the end of the
temperature rise and in the attained temperature.
[0128] The high-frequency heating was individually applied to the
gears 8 one by one while carrying the gears 8 (conveying the gears
8) one by one. The water cooling in the rapid cooling period "d2"
was completed in approximately 13 seconds. The cooling rate during
that period was 50.degree. C./s to 65.degree. C./s. During the
water cooling, the gear 8 was rotated, and the cooling water was
sprayed to the gear 8 from its periphery, thus individually cooling
the gears 8 one by one. In this way, the quenching process was
performed by the method that can suppress the occurrence of
distortion most effectively. The heat pattern shown in FIG. 7 is
also an example, and can be changed, by conducting appropriate
preliminary tests, to a heat pattern of optimal conditions for the
type of steel raw material used. For example, as shown in FIG. 9,
the cooling after the temperature rise may be performed in two
stages.
[0129] Next, description will be made of tests that were conducted
on the gear 8. In the present example, the following three types of
tests were conducted on the gear 8: machinability test, material
quality examination, and fatigue test.
[0130] <Machinability Test>
[0131] As described above, the machinability tests were conducted
when the gears 8 were produced from hot-rolled steel products by
machining. The conditions of the machinability tests were as
follows: lathe is performed in the dry environment by using a
carbide tool at a circumferential speed of 250 m/min, a feed rate
of 0.3 mm/rev, and a depth of cut of 1.5 mm. Under these
conditions, ten of the gears 8 were produced. A case in which the
carbide tool was not chipped was judged as "good", whereas a case
in which the carbide tool was chipped was judged as "poor".
[0132] <Material Quality Examination>
[0133] The material quality examination was conducted on a sample
taken from the tooth wall surface 811 of the gear 8 that had not
been subjected to the fatigue test to be described later after the
completion of the heat treatment. The following two items were
investigated: hardness and crystal grain size. Regarding the
hardness, the Vickers hardness at a load of 2.9 N was measured at
each of depths increased at intervals of 0.05 mm from the surface
of the sample, and an effective depth of the hardened layer
specified in JIS G 0557 was measured. Regarding the crystal grain
size, at a depth of 0.4 mm from the surface of the sample, an
austenitic grain size number specified in JIS G 0551 was obtained
and evaluated.
[0134] The evaluation of material quality was judged based on the
following criteria.
[0135] (Good)
[0136] The material satisfying all of the following three
conditions was judged as "good". [0137] An effective depth of the
hardened layer of 0.8 mm or more is ensured. [0138] No
nonuniformity is present in Vickers hardness. Specifically, the
difference is less than HV50 between every adjacent pair of
measurement points. [0139] Fine grain having an austenitic grain
size number of 6 or more.
[0140] (Poor)
[0141] The material not satisfying any of the above three
conditions was judged as "poor", and the unsatisfactory condition
was identified. Note that, if the material turned out to have very
low strength in the fatigue test to be described later, the
fracture surface thereof was observed with a SEM (scanning electron
microscope) to check whether the fracture surface was formed by
grain boundary brittle fracture.
[0142] <Fatigue Test>
[0143] As fatigue tests, tooth root bending fatigue strength (Nm)
and pitting strength (Nm) were measured by a power circulating type
gear tester. The gears 8 tested had the following dimensions: a
module of 2.03, a pressure angle of 18.degree., and a helix angle
of 27.degree.. The tooth root bending fatigue strength was
evaluated by the amount of input torque that provided a fatigue
life of 10 million cycles under the condition that a lubricating
oil temperature was 80.degree. C. and a rotating speed was 2000
rpm. When the pitting area was 3% or less of the entire tooth
bearing area after 50 million cycles of input torque had been
applied under the condition that a lubricating oil temperature was
120.degree. C. and a rotating speed was 4000 rpm, the pitting
strength was evaluated by the amount of the input torque thus
applied. In both of the tests, ATF (automatic transmission fluid)
was used as lubricating oil.
TABLE-US-00003 TABLE 3 Test Machinability Material Quality Fatigue
Test Result (Input Torque in Nm) No. Test Result Examination Result
Tooth Root Bending Fatigue Pitting Invention 1 Good Good 406 270
Example 2 Good Good 400 253 3 Good Good 418 282 4 Good Good 406 276
5 Good Good 424 288 6 Good Good 419 290 7 Good Good 406 206 8 Good
Good 365 300 9 Good Good 383 276 10 Good Good 412 288 11 Good Good
365 306 12 Good Good 394 222 13 Good Good 377 282 14 Good Good 406
259 15 Good Good 412 282 16 Good Good 371 306 17 Good Good 377 247
18 Good Good 418 282 19 Good Good 406 270 20 Good Good 371 282 21
Good Good 388 300 22 Good Good 377 211 23 Good Good 418 276
TABLE-US-00004 TABLE 4 Fatigue Test Result (Input Torque in Nm)
Test Machinability Material Quality Tooth Root No. Test Result
Examination Result Bending Fatigue Pitting Comparative 24 Good Good
412 194 Example 25 Poor - (Impossible to make gear) machinability
26 Good Nonuniform hardness 330 194 27 Good Nonuniform hardness 325
188 28 Good Nonuniform hardness 324 188 29 Good Grain boundary
brittle 294 164 fracture surface 30 Good Grain boundary brittle 303
165 fracture surface 31 Good Nonuniform hardness 342 200 32 Good
Nonuniform hardness 340 205
[0144] Table 3 (invention examples) and Table 4 (comparative
examples) show results of the tests described above. As shown in
Table 3, the machinability and the material quality of all of the
gears 8 (Test Nos. 1 to 23) of the present invention were found to
be good. The fatigue tests also showed excellent results.
Particularly, in all of the invention examples, the tooth root
fatigue strength was superior to that of the comparative examples,
Test Nos. 31 and 32, that used conventional steel SCM420, and the
pitting strength was comparable with or superior to that of the
comparative examples, Test Nos. 31 and 32.
[0145] FIG. 10 shows details of measurement results of the Vickers
hardness of one of the invention examples, Test No. 3. In FIG. 10,
the vertical axis represents the Vickers hardness, and the
horizontal axis represents the depth from the surface (tooth root
portion 815). According to FIG. 10, the Vickers hardness is
approximately 800 on the surface, and is reduced as the depth
increases. Then, the Vickers hardness remains almost constant at a
depth of 2.6 mm or more. From this result, it is found, in this
example, that the effect of the quenching is exerted on a portion
extending from the surface to a depth of 2.6 mm, and that a portion
at a depth of 2.6 mm or more is the unquenched layer 93. In
addition, in the range from the surface to a depth of 2.6 mm, there
is a stepwise change in the Vickers hardness at a depth of
approximately 0.9 mm. From this result, it is found, in this
example, that the range from the surface to a depth of 0.9 mm is
the carburized layer 91, and the range from a depth of 0.9 mm to a
depth of 2.6 mm is the quench-hardened layer 92. In this way, in
the present invention example, the hardness is increased by the
quenching not only in the carburized layer 91, but also in the
quench-hardened layer 92 therebelow.
[0146] In contrast, in the comparative examples, poor results were
found in all of Test Nos. 24 to 32. Table 4 shows the poor results
in bold italic characters. The individual results are as
follows.
[0147] In Test No. 24, the pitting strength was low. The reason is
considered to be that the resistance to temper softening was
increased insufficiently because the Si amount in the steel raw
material was less than 0.35%.
[0148] In Test No. 25, the gear 8 serving as a test piece could not
be produced because of poor machinability of the raw material. The
reason is considered to be that the raw material was too hard
because the C amount in the steel raw material exceeded 0.40%.
[0149] In each of Test Nos. 26 to 28, the hardness was nonuniform,
and the fatigue strengths (both the tooth root strength and the
pitting strength) were low. The reason is considered to be that
lack of penetration of cementite occurred because the Cr amount in
the steel raw material exceeded 0.2%.
[0150] In Test No. 29, the fatigue strengths (both the tooth root
strength and the pitting strength) were very low. Consequently, the
fracture surface was observed by the SEM and confirmed to be a
grain boundary brittle fracture surface. The reason of the low
fatigue strengths is considered to be that a grain boundary
segregation of P occurred to cause grain boundary brittleness
because the P amount in the steel raw material exceeded 0.03%.
[0151] In Test No. 30, the fatigue strengths (both the tooth root
strength and the pitting strength) were very low. Consequently, the
fracture surface was observed by the SEM and confirmed to be a
grain boundary brittle fracture surface. The reason of the low
fatigue strengths is considered to be that a grain boundary
segregation of S occurred to cause grain boundary brittleness
because the S amount in the steel raw material exceeded 0.15%.
[0152] In Test Nos. 31 and 32, the hardness was nonuniform, and the
tooth root fatigue strength was low. These comparative examples
used the conventional steel SCM420 (chromium-molybdenum steel). The
reason of the low fatigue strength is considered to be that lack of
penetration of cementite occurred because both of the Cr amount and
the Mo amount were excessive. Particularly, the pitting strength
was also slightly low in Test No. 31. The reason is considered to
be that the Si amount in the steel raw material was
insufficient.
[0153] From comparison between the present invention examples and
the comparative examples, it has become clear that, compared with
the conventional chromium-molybdenum steel, the gear 8 and the
manufacturing method thereof of the present invention provide
higher tooth root fatigue strength, and the same or superior
characteristics in other respects, in spite of using less amounts
of Cr and Mo to reduce material cost.
[0154] Note that the present embodiment and the example are only
illustrative examples, and do not limit the present invention.
Accordingly, as a matter of course, various improvements and
modifications can be made to the present invention without
departing from the gist thereof. For example, in the
above-described example, description has been made of an external
gear, as the gear 8, in which the tooth portions 81 are formed
outward. However, the present invention is not limited to the
external gear, but can be applied to an internal gear (such as a
ring gear of a planetary gear device) as shown in FIG. 11, or to a
bevel gear. Regarding the positional relationships of the
quench-hardened layers and others, it should be noted that, in the
case of the internal gear, the outside in the radial direction
corresponds to the expression "below" or "deep". Note that,
although FIG. 11 is drawn with a part of the gear omitted, tooth
profiles are actually formed over the entire circumference, as a
matter of course.
* * * * *